Floor element for forming a floor covering, a floor covering, and a method for manufacturing a floor element

ABSTRACT

A floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer arranged below the decorative layer, wherein the support layer comprises edges provided with coupling elements configured to allow a mechanical coupling with coupling elements of an adjacent floor element, wherein the floor element comprises an intermediate layer having a resin material that permeates a lower surface of the decorative layer, and wherein the intermediate layer is an adhesive layer that bonds together the decorative layer and the support layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority to, U.S.patent application Ser. No. 16/028,745, filed on 6 Jul. 2018, thedisclosure of which is herein incorporated by reference in its entirety.

BACKGROUND 1. Field

The present invention relates to a floor element for forming a floorcovering, a floor covering, and a method for manufacturing a floorelement.

More particularly, the invention is related to a floor element forforming a floor covering, wherein this floor element comprises adecorative layer made of a brittle material such as natural stone, glassor sintered ceramic materials like porcelain, earthenware or the like.The decorative layer can, for example, be a ceramic tile.

2. Background

Traditionally, ceramic tiles are installed by laying them side by sideon a surface such as a floor or wall. Typically, an adhesive compound isused to attach the tiles to the surface. Seams between the tiles aregrouted. In this way, the tiles are bonded to a rigid surface, forexample a concrete subfloor, thereby improving their impact strength.The bound with the subfloor, and thus also with the structure of thedwelling, also leads to a high attenuation of walking sounds, both inthe room where the floor is installed, and in quarters below therespective room. The tiled surface is water impervious and hygienic,since it can be cleaned in a very wet manner. The step of installing thetiles with an adhesive is, however, labor intensive and represents asignificant portion of the labor involved in a typical floor coveringinstallation. Moreover, this installing technique requires a highprofessional competence in order to obtain a well levelled floorcovering. Thus, due to the time and labor involved in the installation,it is typically quite costly to have tiles professionally installed.

To substitute an existing floor covering made of tiles, it is oftennecessary to break the tiles, regenerate the surface by removing theresidues of adhesive and then install a new floor covering. Thus, thedemolition of a floor covering made of tiles is a labor andtime-consuming operation. If the aim of the restoration is to substituteonly one or a few damaged tiles, this operation becomes also difficult,since the substitution of one tile preferably does not damage theadjacent tiles.

In recent years, manufacturers have attempted to produce do-it-yourselftiling solutions that are easier to install. Some examples of theseattempts are shown in WO 2004/097141 and WO 2008/097860. The floorelements disclosed in those documents can be laid on a surface andmechanically coupled together to form a floor covering without the useof an adhesive, thereby reducing the labor and time of the installingphase. Such kind of floor covering is known as a floating floorcovering. In particular, in these documents, a ceramic tile or naturalstone slab is fixed to a support layer that comprises coupling elementsconfigured to realize a coupling with coupling elements of an adjacentfloor element, thereby forming a floor covering.

On the other hand, since such floor elements are not bonded to a commonrigid surface, the impact strength and, consequently, the fatiguestrength is significantly reduced. The floating installation may alsogive rise to louder walking noise. The joints between the tiles of WO2008/097860 may be prone to water penetration especially upon wetcleaning. According to some embodiments of WO 2004/097141, grout may beapplied in the joints available between adjacent floor elements, whichmay lead to water imperviousness of the respective joint.

To improve the impact resistance of ceramic tiles, US 2014/349084suggests a tile with a composite build-up. In this composite tile, areinforcing layer is arranged in between two ceramic layers or inbetween a ceramic layer and a polymer laminate. As example of areinforcing layer, a fiberglass layer is mentioned. The installation ofthis tile is, however, still cumbersome. A bonding with an underlyingsubfloor is required, for example via a bottom layer with pressuresensitive adhesive or tack fast loop fabric so that the tile issubstantially made solid with the subfloor for improving the impactstrength. Moreover, a precise positioning of the tile is difficult.

WO 2010/072704 proposes a different type of reinforcing layer, namely asteel plate. This steel plate is adhered to the back surface of theceramic tile or slab. Also here, the installation is, however,difficult. The installation is done by simply resting the tiles on asubfloor, so that a precise positioning of the tile is difficult and thefloor covering results in a not well levelled surface and in a noisy andpermeable floor covering.

The present invention aims in the first place to provide an alternativefloor element, which, in accordance with several of its preferredembodiments, is directed to solve one or more of the problems arising inthe state of the art.

BRIEF SUMMARY

In one aspect, the present invention provides a floor element forforming a floor covering, wherein the floor element comprises adecorative layer made of a ceramic material; a support layer arrangedbelow the decorative layer; and an intermediate reinforcing layercomprising a resin material that permeates a lower surface of thedecorative layer, wherein the support layer comprises edges providedwith coupling elements configured to realize a mechanical coupling withcoupling elements of an adjacent floor element and wherein theintermediate reinforcing layer is an adhesive layer that bonds thedecorative layer and the support layer together.

In some embodiments, the decorative layer has a volume of open porescomprised between 0.01 cc and 1 cc measured according to ASTM C373.

In some embodiments, the brittle material is selected from the groupcomprising natural stone, glass or sintered ceramic materials. In someembodiments, the decorative layer comprises a ceramic tile.

In some embodiments, the resin material comprises epoxy. In someembodiments, the resin material has a viscosity less than 1000 Pas at20° C.

In some embodiments, the intermediate reinforcing layer covers 80percent or more of the lower surface of the decorative layer. In someembodiments, the intermediate reinforcing layer comprises a resincontent of at least 150 g/sqm.

In some embodiments, the decorative layer has an apparent porositycomprised between 0.1% and 10% measured according to ASTM.

In some embodiments, the support layer comprises rigid PVC. In someembodiments, the support layer comprises more than 30 wt % of fillers.In some embodiments, the support layer has a flexural modulus between1.5 and 3.5 GPa. In some embodiments, the support layer has a thicknessless than 6 mm.

In some embodiments, the floor element comprises a superficial area ofless than 1.5 sqm, preferably less than 1 sqm, more preferably less than0.4 sqm. In some embodiments, the weight of the floor element is atleast 18 kg/sqm.

In some embodiments, the coupling elements are configured in such a waythat in a coupled condition a play is established between coupledcoupling elements

In another aspect, the present invention provides a floor coveringcomprising a plurality of floor elements as described herein.

In another aspect, the present invention provides a method formanufacturing a floor element, the method comprising: providing adecorative layer made of a brittle material; providing a support layer;providing a resin material for bonding the decorative layer and thesupport layer together; and pressing the layers together for forming thefloor element such that the resin material permeates the ceramic layer.

In some embodiments, the pressure is maintained for a pressing time ofat least 1 second. In some embodiments, a pressure of at least 350kg/sqm is applied the decorative layer and the support layer during thepressing step.

BRIEF DESCRIPTION OF THE FIGURES

The following non-limiting and exemplary figures are provided to showseveral possible forms of embodiments according to the disclosure.

FIG. 1 shows a top view of an embodiment of a floor element of theinvention;

FIG. 2 on a larger scale shows a cross section along the line II-II ofFIG. 1;

FIG. 3 on a larger scale shows a view on the area F3 indicated on FIG.2;

FIG. 4 on a larger scale shows a cross section along the line IV-IV ofFIG. 1;

FIG. 5 on a smaller scale shows a top plane view of a floor coveringcomprising a plurality of the floor elements of FIG. 1;

FIG. 6 on a larger scale shows a cross section along the line VI-VI ofFIG. 5;

FIG. 7 on a larger scale shows a view on the area F7 indicated on FIG.6;

FIG. 8 on a larger scale shows a cross section along the line VIII-VIIIof FIG. 5;

FIG. 9 on a larger scale shows a view on the area F9 indicated on FIG.8;

FIG. 10 shows some steps of a method for manufacturing a floor element.

DETAILED DESCRIPTION

To facilitate an understanding of the principles and features of thevarious embodiments of the invention, various illustrative embodimentsare explained below. Although exemplary embodiments of the invention areexplained in detail, it is to be understood that other embodiments arecontemplated. Accordingly, it is not intended that the invention islimited in its scope to the details of construction and arrangement ofcomponents set forth in the following description or examples. Theinvention is capable of other embodiments and of being practiced orcarried out in various ways. Also, in describing the exemplaryembodiments, specific terminology will be resorted to for the sake ofclarity.

It must also be noted that, as used in the specification and theappended claims, the singular forms “a,” “an” and “the” include pluralreferences unless the context clearly dictates otherwise. For example,reference to a component is intended also to include composition of aplurality of components. References to a composition containing “a”constituent is intended to include other constituents in addition to theone named. In other words, the terms “a,” “an,” and “the” do not denotea limitation of quantity, but rather denote the presence of “at leastone” of the referenced item.

As used herein, the term “and/or” may mean “and,” it may mean “or,” itmay mean “exclusive-or,” it may mean “one,” it may mean “some, but notall,” it may mean “neither,” and/or it may mean “both.” The term “or” isintended to mean an inclusive “or.”

Also, in describing the exemplary embodiments, terminology will beresorted to for the sake of clarity. It is intended that each termcontemplates its broadest meaning as understood by those skilled in theart and includes all technical equivalents which operate in a similarmanner to accomplish a similar purpose. It is to be understood thatembodiments of the disclosed technology may be practiced without thesespecific details. In other instances, well-known methods, structures,and techniques have not been shown in detail in order not to obscure anunderstanding of this description. References to “one embodiment,” “anembodiment,” “example embodiment,” “some embodiments,” “certainembodiments,” “various embodiments,” etc., indicate that theembodiment(s) of the disclosed technology so described may include aparticular feature, structure, or characteristic, but not everyembodiment necessarily includes the particular feature, structure, orcharacteristic. Further, repeated use of the phrase “in one embodiment”does not necessarily refer to the same embodiment, although it may.

Ranges may be expressed herein as from “about” or “approximately” or“substantially” one particular value and/or to “about” or“approximately” or “substantially” another particular value. When such arange is expressed, other exemplary embodiments include from the oneparticular value and/or to the other particular value. Further, the term“about” means within an acceptable error range for the particular valueas determined by one of ordinary skill in the art, which will depend inpart on how the value is measured or determined, i.e., the limitationsof the measurement system.

By “comprising” or “containing” or “including” is meant that at leastthe named compound, element, particle, or method step is present in thecomposition or article or method, but does not exclude the presence ofother compounds, materials, particles, method steps, even if the othersuch compounds, material, particles, method steps have the same functionas what is named.

It is also to be understood that the mention of one or more method stepsdoes not preclude the presence of additional method steps or interveningmethod steps between those steps expressly identified. Similarly, it isalso to be understood that the mention of one or more components in acomposition does not preclude the presence of additional components thanthose expressly identified.

The materials described hereinafter as making up the various elements ofthe present invention are intended to be illustrative and notrestrictive. Many suitable materials that would perform the same or asimilar function as the materials described herein are intended to beembraced within the scope of the invention. Such other materials notdescribed herein can include, but are not limited to, materials that aredeveloped after the time of the development of the invention, forexample. Any dimensions listed in the various drawings are forillustrative purposes only and are not intended to be limiting. Otherdimensions and proportions are contemplated and intended to be includedwithin the scope of the invention.

Embodiments of the Invention

Thereto, the present invention, according to a first independent aspect,relates to a floor element for forming a floor covering, wherein thisfloor element comprises a decorative layer made of a ceramic materialand a support layer arranged below this decorative layer, wherein thesupport layer comprises edges provided with coupling elements configuredto realize a mechanical coupling with coupling elements of an adjacentfloor element and wherein the floor element comprises an intermediatelayer having a resin material that permeates a lower surface of thedecorative layer. The inventors have found that, due to this solution,the impact resistance of the floor element, more particularly of thedecorative layer of ceramic, is highly increased, so that, even with themechanical locking between such floor elements, the impact strengthachieves or even exceeds the impact strength of the traditional elementsinstalled by means of adhesives. Moreover, with the claimed solution itis possible to improve the impact resistance of the floor elementwithout the necessity to add further rigid or resilient reinforcingelements like rubber layer, fiberglass or metal plates. In fact, theresin permeating the pores of the decorative layer substantiallyimproves the transmission and dissipation of the impact stress throughthe floor element so that a lower portion of said energy is absorbed bythe decorative layer improving the impact resistance thereof. Since itis not necessary to add rigid reinforcing elements, the resulting floorelement is lighter and thinner. Moreover, the resin constitutes a hinderto the propagation of cracks in the decorative layer itself.Furthermore, in case of superficial cracks of the decorative layer, theintermediate layer keeps the decorative layer itself coherent, andpreferably compacted, thereby disguising the visual appearance of thesuperficial cracks.

Impact strength for flooring can be determined by means of a steel ballimpact test. According to this test the impact strength is measured bydropping a steel ball on the floor element from a certain height, if thefloor element does not break the height is increased until a height isreached where the steel ball breaks the floor element. The steel ballhas a weight of 225.5 grams and a diameter of 38.1 mm (1.5 inches). Theimpact strength is expressed in terms of the maximum attainable heightfrom which the steel ball, when dropped on the floor element does notbreak the floor element. The higher the drop height, the higher is theimpact strength. The impact strength can be expressed in Joule (J), i.e.the energy of the steel ball when hitting the surface of the floorelement. The inventors have found that traditional floorings, forexample floorings made of porcelain floor elements with a thickness ofapproximately 10 mm, directly glued to a subfloor, usually show impactstrength comprised between 1.68 J and 2.25 J (corresponding to a ballfalling from a height comprised between 762 and 1016 mm) whereas knownfloating floors show an impact strength usually lower than 1.12 j(corresponding to a ball falling from a height lower than 508 mm). Theinventors have found that, due to this solution, an impact strengthabove 5.62 J (corresponding to a fall of the steel ball from a height ofabove 2540 mm) can be achieved.

Fatigue strength for flooring is determined by means of the so-calledRobinson Test according to ASTM C627. According to this test athree-wheel cart rotates about its center on top of a sample section ofa tiles floor. Above each wheel is a rod along which weights can bestacked. A power motor drives the assembly and the cart rotates at arate of 15 revolutions per minute. The test is run according to aloading schedule with 14 different cycles. For each cycle, the schedulespecifies a type of wheel to be used (soft rubber, hard rubber, orsteel), the amount of weight to be stacked above each wheel, and thetotal number of cart revolutions to be executed. After the completion ofeach cycle, the sample floor section is visually examined. The testresult qualifies the floor according to the number of cycles passedwithout failure and indicates the following service level to which thefloor is destined:

-   -   Sample completing cycles 1 through 3 without failure:        “Residential” rating;    -   Samples completing cycles 1 through 6: “Light” commercial        rating;    -   Samples completing cycles 1 through 10: “Moderate” commercial        rating;    -   Samples completing cycles 1 through 12: “Heavy” commercial        rating;    -   Samples completing all 14 cycles without failure are assigned in        “Extra heavy” commercial rating.        The inventors have found that due to the use of the intermediate        layer according to the invention, the Robinson Test can result        in passing 6 cycles (Light Commercial) as minimum.

In accordance with an embodiment of the invention, the decorative layercomprises a ceramic body, for example made of porcelain, red bodyceramic, stoneware, earthenware, or other sintered ceramic powders.Preferably, the decorative layer is a ceramic tile or slab. With“ceramic tile” an element is meant with a substantially flat bodyconsisting of baked minerals, such as clay, and preferably with a fireddecorative top surface, preferably but not necessarily, on the basis ofa glaze. The glaze has also the effect of preventing the resinpermeating the decorative layer from reaching the upper surface of thedecorative layer thereby affecting the appearance of the floor element.

It is noted, however, that this first aspect can be advantageouslyapplied with decorative layers being made of any kind of materialshowing an open porosity at least in correspondence of its lowersurface. Examples of said material can be brittle material, such asnatural stone, concrete, glass or glass-ceramic material. With brittlematerial is intended a material that breaks without significant plasticdeformation. In particular, for the scope of said patent application,with the term brittle material is intended a material that of its own(if not bonded to a support layer and without any reinforcing element)has an impact strength lower than 1.68 J (corresponding to a ballfalling from a height lower than 762 mm) according to the ball impacttest.

According to a preferred aspect of the invention the decorative layermay comprise, at least in correspondence of its lower surface, an openporosity adapted to allow the resin to permeate the decorative layeritself. In fact, as already indicated above the inventors havesurprisingly found that by making the resin of the intermediate layerpermeating the pores of the decorative layer it is possible tosignificantly improve the transfer of the impact energy. Thus, accordingto a preferred embodiment of the invention the decorative layercomprises an apparent porosity between 0.1% and 10% determined accordingto ASTM C373, more preferably between 2% and 8%, for example 6%. Theabovementioned ranges and values of apparent porosity provide theoptimum balance between intrinsic mechanical properties of thedecorative layer and the resin permeability thereof thereby optimizingthe impact strength. In fact, the pores of the material, especially theclosed pores that cannot be permeated by the resin may represent weakpoints of the material itself, therefore it is preferable that thedecorative layer comprises an apparent porosity lower than 15%,preferably lower than 10% measured according to ASTM C373. Furthermore,the decorative layer may preferably have a volume of the open porescomprised between 0.01 cc (cubic centimeter) and 1 cc, more preferablybetween 0.10 cc and 0.90 cc, for example 0.60 cc. In this way the poresare big enough to be filled by the resin while at the same time they aresufficiently small to not compromise the mechanical properties of thedecorative layer. This result is particularly impressive since theapparent porosity range is specific for ceramic tiles that are usedmainly for wall covering or for floor covering in residentialinstallations, but for floor covering of commercial installations wherethe traffic is more intense and higher mechanical properties arerequired, it is preferred the use of ceramic tiles having apparentporosity.

Thus, according to a first preferred possibility the decorative layer ismade of porcelain. Porcelain is a ceramic material obtained by firing athigh temperature, for example around 1200° C., a mixture of relativelypure raw material comprising clays, kaolin, quartz, feldspar, calciumcarbonate and/or other mineral raw materials. Porcelain shows a very lowapparent porosity, preferably less than 1%, for example 0.3% measuredaccording to ASTM C373. Porcelain has a volume of the open porescomprised between 0.01 cc (cubic centimeter) and 0.1 cc, more preferablybetween 0.1 cc and 0.6 cc. Said porosity values are such that theporcelain material shows relatively high mechanical properties that canbe further increased due to the resin permeating the decorative layer.In fact, a porcelain tile as such, i.e. when not bonded to a supportlayer and without the resin permeating the decorative layer, shows animpact resistance of 0.73 J, whereas a floor element comprising adecorative layer made of porcelain bonded above a support layer by meansof an intermediate layer comprising a resin that permeates the lowersurface of the decorative layer can reach an impact resistance up to3.37 J.

Therefore, according to a second preferred possibility the decorativelayer is made of a red body ceramic tile. Red body ceramic is a ceramicmaterial obtained by firing at high temperature, for example around1150° C., of a raw material mixture comprising clays, kaolin, quartz,feldspar, calcium carbonate and/or other mineral raw materials. Red bodyceramic may be fired at lower temperature with respect to porcelainthereby showing a higher porosity and water absorption rate. Moreover,red body ceramic is obtainable starting from a raw material mixture thatis cheaper than the raw material mixture that is necessary to obtainporcelain. For example, red body ceramic may comprise an apparentporosity comprised between less than 10%, preferably between 2% and 8%,for example 6% measured according to ASTM C373. Red body ceramic mayhave a volume of the open pores comprised between 0.10 cc and 0.90 cc,for example 0.60 cc. Usually a red body ceramic tile as such, i.e. whennot bonded to a support layer and without the resin permeating thedecorative layer, shows an impact resistance of 0.67 J, whereas a floorelement comprising a decorative layer made of red body ceramic bondedabove a support layer by means of an intermediate layer comprising aresin that permeates the lower surface of the decorative layer can reachan impact resistance up to 5.62 J. It is to be noted that a red bodyceramic tile as such has an impact resistance lower than a porcelaintile as such, whereas a floor element according to the invention andcomprising red body ceramic shows a significantly higher resistance thana floor element comprising porcelain.

The inventors have found that the interaction between the resin and thedecorative layer is improved if the decorative layer comprises a lowersurface that is substantially flat. The lower surface is the non-visiblesurface (in use) that is opposite to the upper decorative surface of thedecorative layer. Usually, the lower surface of a ceramic tile comprisesribs that can have a thickness up to 1 mm, but the inventors have foundthat for the application of the resin to the lower surface itself it ispreferred to use a decorative layer that is free from said ribs.Furthermore, according to a preferred embodiment of the invention thelower surface of the decorative layer, in particular of the ceramictile, is free from backwash. The backwash is a thin coating basicallycomprising an engobe that is applied to the lower surface of the ceramictile and has the function of preventing the material of the non-firedceramic tile from sticking onto the rollers of the firing kiln. Sincethe backwash comprises an engobe that is at least partially composed bya glass composition, during firing of the ceramic tile it meltspermeating the pores of the ceramic tile that are open on the lowersurface thereof so that the lower surface itself becomes impermeable.Thus, the inventors have found that a decorative layer made of a ceramictile having a lower surface free from backwash provides a better resinpermeability of the lower surface of the ceramic tile. It is alsopossible that the backwash covers a portion of the lower surface of thedecorative layer that is lower to the 20%, preferably the 10% of saidlower surface. In this way the backwash does not totally impermeabilizethe lower surface allowing the resin to permeate said porosity of thedecorative layer, while on the other hand helps the manufacturing of thedecorative layer preventing the material of the non-fired ceramic tilefrom sticking onto the rollers of the firing kiln.

The decorative layer has an upper face comprising a décor. The décor canbe provided with a variety of textures, designs and colors. In apreferred embodiment, the décor simulates a natural product, such asnatural stone or wood. Preferably, the décor is at least partiallyformed by a print. The print is preferably realized by means of digitalprinting, such as inkjet printing, although screen printing,rotogravure, flexography or off-set printing is not excluded. Accordingto a variant, the décor is at least partially formed by uniformlycolored base material or by a mix of colored base materials.

The decorative layer can comprise a background coating covering at leastpartially its upper surface and adapted to receive the décor on its top,for example adapted to receive the print on its top. The backgroundcoating can be white, beige, brown or of any color suitable to receive adécor on its top. In the case that the decorative layer is made of aceramic material, the background layer preferably comprises at least aglaze covering the upper surface of the ceramic body.

The decorative layer can also comprise a protective coating covering atleast partially its upper surface and being adapted to be placed abovethe décor. The protective coating can be transparent or translucent. Itis clear that the protective coating can be used in combination with thebackground coating. In the case that the decorative layer is made of aceramic material, the protective layer preferably is a glaze.

Preferably, the decorative layer has a thickness comprised between 4 and15 mm, for example 6 mm, preferably more than 7 mm, for example 8 or 10mm. The inventors have found that by adding an intermediate layer asatisfying fatigue behavior can be achieved for a relatively thindecorative layer.

It is noted that the decorative layer may comprise density as expressedby surface weight of at least 10 kg/sqm, preferably 15 kg/sqm, forexample more than 19 kg/sqm. High density of the decorative layer mayimprove installation of the floor covering and in particular a verticallocking of between the floor elements as it will be described below inmore detail. It is also preferred that the decorative layer comprises adensity as expressed by surface weight of less than 35 kg/sqm,preferably less than 30 kg/sqm, for example less than 25 kg/sqm. Infact, an excessively heavy decorative layer may affect themaneuverability of the floor element as well as complicating thepackaging and the transportation thereof.

It is clear that the decorative layer can be made of any shape, forexample a squared, rectangular or hexagonal shape. In a preferredembodiment, the floor elements are rectangular and oblong in shape, andare preferably provided with a wood grain print depicting wood grainlines extending globally in the longitudinal direction of therectangular decorative layer. The covering element may further compriseany dimension, although it is preferred that it comprises a superficialarea of less than 1.5 sqm, preferably less than 1 sqm, more preferablyless than 0.4 sqm.

In accordance with a preferred aspect of the invention the intermediatelayer comprises a resin, for example a thermosetting resin orthermoplastic resin. Examples of thermosetting resin are epoxy,polyurethane, cyanoacrylate or acrylic resin. Examples of thermoplasticresin are hot melt, polyester thermoplastic, vinyl etc. Preferably theresin is a rigid resin. In fact, the inventors have found that a rigidresin, rather than flexible resin, improves the transfer of the impactenergy between the layers. In particular, according to a preferredembodiment of the invention the intermediate layer comprises an epoxyresin. It is also preferred that the epoxy is a bicomponent resin, i.e.a thermosetting resin obtained by curing at low temperature (for exampleat room temperature) a mixture of two components, namely a resin and ahardener. When the two components of the resin are mixed together thecuring reaction starts so that it is not necessary to activate the cureby providing external energy, like heat, UV or EB radiation. Saidexternal energy could be optionally provided in order to accelerate thecuring process. According to a preferred aspect of the invention theresin comprises a viscosity at 20° C. less than 1000 Pas, preferablyless than 800 Pas, more preferably less than 600 Pas, for exampleapproximately 400 Pas. Within the scope of the invention viscosity meansthe viscosity of the uncured resin, for example the viscosity of themixture of the two components before the completion of the curing, i.e.during the so-called pot life. In fact, the inventors have found that ifthe resin is sufficiently fluid, during its application onto the back ofthe decorative layer, it can permeate the pores thereof extremelyimproving the bonding between the intermediate layer and the decorativelayer. In practice the when the resin permeates the pores of thedecorative layer it substantially forms a “composite polymer-ceramiclayer” that significantly improves the impact strength of the floorelement. It is noted that, according to a preferred solution the resinis in a substantially liquid state during the manufacturing process ofthe floor element. It is not excluded that the resin is in a pasty orgel state during the manufacturing process, for example showing athixotropic behavior in order to reach a sufficient fluidity to permeatethe pores of the decorative layer under predetermined processconditions, for example during a pressing step. According to anembodiment of the invention the intermediate layer may comprise two ormore different resins. For example, the intermediate layer may comprisea first resin for impregnating the pores of the decorative layer and asecond resin for bonding together the decorative layer and the supportlayer. According to said embodiment the first resin may be a rigid resinfor reinforcing the decorative layer and the second resin may be a forexample a soft or elastomeric resin that provides a cushioning effect incase of impact.

The inventors have also found that preferably the resin may be free fromfillers, like mineral fillers. In fact, the inventors have found thatthe presence of fillers if on one hand improves mechanical properties ofthe resin as such, on the other hand increases the viscosity of theresin thereby forming an obstacle to the permeation of the decorativelayer.

The resin preferably comprises a tensile strength between 50 and 90 MPa,more preferably between 60 and 80 MPa, for example 75 MPa. It is notedthat the resin preferably comprises a compressive strength between 90and 130 MPa, more preferably between 100 and 120 MPa, for example 110MPa. The inventors have found that such strength is sufficient toprovide a rigid matrix for the composite polymer-ceramic layer thatallows dissipation of the impact energy. It is also noted that the resinmay preferably show a hardness value of at least 50 measured on a ShoreD scale.

Preferably the resin covers at least a portion of the lower surface ofthe decorative layer, for example the majority, i.e. at least 50percent, of the lower surface of said decorative layer. More preferablythe resin covers 80 percent or more of the lower surface of thedecorative layer, for example it covers the 100 percent of the lowersurface of the decorative layer so that the effect of distribution anddissipation of the impact energy is obtained for an impact occurring inany point of the decorative layer.

The resin is preferably provided onto the lower surface of thedecorative layer in an amount greater than 150 g/sqm, more preferablygreater than 200 g/sqm, for example 220 g/sqm so that the resin is in anamount that is sufficient to fully permeate the open pores of the lowersurface of the decorative layer.

It is also preferable that the resin is provided in an amount sufficientto overflow from the open porosity of the decorative layer in order toact as a glue for the support layer. In other words, it is preferablethat the resin partially permeates the open porosity of the decorativelayer and partially coats the lower surface thereof for forming theintermediate layer and improving the transfer of energy. Said effect oftransfer of energy is further improved if the support layer is directlyfixed to the intermediate layer and, in particular, to said portion ofthe resin that coats the lower surface of the decorative layer, so thatthe intermediate layer acts as an adhesive layer that bonds together thedecorative layer and the support layer.

Further, the intermediate layer may comprise a reinforcing element. Thereinforcing element may be embedded into the intermediate layer, forexample embedded into the resin material or may be a reinforcing layerplaced between the intermediate layer and the support layer. Thereinforcing element may comprise fibers like glass fibers carbon fibers,polymeric fibers, for example aramid or polyamide fibers, or ceramicfibers, for example boron or silicate fibers. The fibers may be woven ornon-woven fibers, for example with fibers disposed at differentorientations, and may be in in form of mat, fleece or cloth. Saidreinforcing element may be used to further improve the impact resistanceof the floor elements especially in case of special and peculiarinstallation like raised floors.

According to an alternative embodiment the reinforcing element maycomprise a metal plate, for example a steel or aluminum plate.Preferably, the metal plate is configured to establish a compressivestate in the decorative layer. In this way, since the decorative layeris in a compressive state, the impact resistance is strongly improved,because the compression obstacles the propagation of cracks and helps indisguising the visual effect of superficial cracks. To achieve thisgoal, the metal plate is first stretched, for example by means of amechanical or thermal stretching, and then is bonded to the decorativelayer while the metal plate is in the stretched state. Subsequently, thestretch is released, by interrupting the mechanical solicitation or bycooling the metal plate itself, thereby establishing a compressive statein the decorative layer. For example, embodiment, the metal plate has acoefficient of thermal expansion higher than the coefficient of thermalexpansion of the decorative layer. Due to this solution, the reinforcingelement is heated to a stretched state, and then it is bonded to thedecorative layer while it is still in the stretched state andsubsequently it is cooled down to retract and put the decorative layerin compression.

According to a preferred embodiment of the invention, the support layeris made of a material that is different from the material of thedecorative layer. More particularly, the support layer is preferablymade of a material adapted to be provided with coupling elements and/ormade of a waterproof material and/or made of a compressible material.

The support layer is preferably made of a polymeric material. Polymericmaterials have good mechanical properties in combination with relativelow cost and low weight and, further, they provide for an impermeableand a sound reducing support layer.

Preferably, the support layer is made of a thermoplastic polymericmaterial, preferably with a glass transition temperature (Tg) less than100° C., for example of PVC (polyvinyl chloride) or polyurethane, moreparticularly thermoplastic polyurethane. Forming the support layer outof a material with a relatively low glass transition temperature leadsto a support layer which is easily compressed at room temperature.Compression is desirable in many respects. For example, a possiblethermal expansion of the support layer may be partially or whollysuppressed by the more rigid or stiffer decorative layer and/orreinforcing element that holds the material of the support layer in itsoriginal dimension. Compression is also interesting for the design ofthe coupling elements and allows for a certain adaptation to unevennessof the subfloor, which in its turn prevents air chambers in between thesupport layer and the subfloor that may amplify walking noises.

Between the thermoplastic materials PVC is a preferred choice for thesupport layer due to the balance between processability, physical andmechanical properties and cost. Moreover, the inventors have found thatPVC shows a good affinity with epoxy resin so that it is possible toform a very good bonding and interphase between the support layer andthe intermediate layer. This interphase improves the transfer of impactenergy between the layers of the floor element thereby improving impactstrength thereof. Moreover, the inventors have found that due to theinteraction between PVC and epoxy resin it is possible to reduce oravoid any delamination effect between the support layer and theintermediate layer, and this has the consequence of improving thefatigue resistance of the floor element. In fact, since the supportlayer and the intermediate layer generally are not separated from eachother because of the delamination, the floor element can maintainsubstantially unaffected its mechanical properties even after prolongedsolicitation, thereby showing good fatigue strength.

In a preferred embodiment, the support layer is made either of a rigidor of a flexible PVC, wherein rigid PVC comprises an amount ofplasticizer lower than 15 phr, and flexible PVC comprises an amount ofplasticizer of 15 phr or more, preferably more than 20 or more than 25phr. Within the context of the present description, “rigid” means thatthe support layer, taken alone, bends under the own weight thereof lessthan 10 cm per meter and still better less than 5 cm per meter, whereasthe “flexible” means that the support layer, taken alone, bends underthe own weight thereof more than 10 cm per meter. The support layer mayalso comprise a high amount of filler materials, such as chalk, e.g.more than 30 wt % or more than 60% wt of such filler materials. Thefillers add weight to the support layer and make the support layer veryeffective in killing the transit of walking sound to lower quarters. Thecontent of filler should be preferably limited to less than less than 60wt %, preferably less than 50 wt % in order to not excessively increasebrittleness of the support layer. Rigid PVC provides for a support layerhaving good dimensional stability when exposed to variation of thetemperature. In other words, the expansion of the support layer, whenexposed to high temperature, is limited thereby providing a goodstability of the floor. A support layer made of flexible PVC has a lowerdimensional stability but is more easily compressed and therefor itstendency to expand can be suppressed at least to some extent by thedecorative layer and/or the intermediate layer.

The inventors have found that best results in terms of impact strengthare achievable by means of a support layer made of rigid polymericmaterial such as rigid PVC. Therefore, according to a preferredembodiment, the support layer is made of a rigid PVC that may comprise aflexural modulus between 1.5 and 3.5 GPa, for example, approximately 2.6GPa. The support layer may also comprise a flexural strength between 60and 90 MPa, for example approximately 76 MPa. Moreover, the supportlayer may comprise a compressive strength between 40 and 70 MPa, forexample approximately 56 MPa. In fact, the inventors have found that therigidity of the support layer helps absorbing the impact energy therebyimproving the impact strength.

According to a different embodiment, a support layer made of flexiblePVC, or from any other material, thermoplastic or not, can be designedin such a way to compensate to variations of dimension due to variationsof the temperature. For example, the support layer can be formed of aplurality of separated elements, for example strips, or can comprisesgrooves separating adjacent portions of the support layer therebypermitting the expansion of said portions without affecting the globalstability of the floor.

Furthermore, the support layer has preferably a thickness comprisedbetween 2 and 7 mm, preferably less than 6 mm, more preferably about 4or less. For example, a preferred embodiment of the invention providesfor a support layer made of rigid PVC and showing a thickness of 4 mm,thereby representing a good solution in terms of thermal stability,noise reduction, low weight and low cost.

Thus, the thickness of the floor element is less than 20 mm, preferably18 mm or less, more preferably 13 mm or less. In this way, the thicknessof the resulting floor element is relatively thin, so that the impact ofthe floor in the environment is reduced, especially in case ofrestoration of existing flooring. Moreover, in this way, the surfaceweight of the floor element is limited so that the packaging, thetransport and the installation are made easier. For example, the surfaceweight of the floor element is at least 18 kg/sqm, preferably at least21 kg/sqm. For example, in a preferred embodiment wherein the decorativelayer is made of porcelain and comprises a thickness of 8.5 mm andwherein the support layer is made of PVC and comprises a thickness of 4mm, the surface weight of the floor element is approximatively 24kg/sqm. Due to this there is a good balance between economy of transportand packaging and easiness of installation. In fact, a weight above saidlimits may help the coupling between two floor elements, especiallyimproving a vertical locking between them.

As mentioned before, the support layer comprises edges with couplingelements configured to realize a mechanical coupling with couplingelements of an adjacent floor element. In the term a “mechanicalcoupling”, a coupling is to be understood that allows adjacent floorelements to be coupled each other without the need for glue or the like.A mechanical coupling may be attained by means of profiled edge contourscomprising coupling elements, mostly a male and a female part, that fitinto each other. It is noted that, preferably, the coupling elements areconfigured such that said mechanical coupling results in a lockingbetween said edges in vertical and/or one or more horizontal directions.

The coupling elements preferably comprise at least a male part and atleast a female part, wherein such male and female part in the connectedstate of two such floor elements have been engaged into each other. Themale and the female parts are preferably at least partially formed inthe support layer. For example, the male and/or female part may bewholly formed in said support layer. Said male and female part in aconnected state of two similar floor elements engage into each other tocreate a mechanical coupling between the respective edges, preferablyresulting in a locking between said edges in vertical and/or one or morehorizontal directions.

As used herein, the terms “horizontal” and “vertical” are basicallyexpressed regarding a floor covering installed on a surface which isconsidered to be horizontal in its general meaning. Thus, when usedregarding a single floor element which is a substantially flat elementprovided with a main plane, the terms “horizontal” and “vertical” are tobe considered respectively equivalent to the terms “parallel withrespect to the main plane of the floor element/installed floor elements”and “perpendicular with respect to the main plane of the floorelement/installed floor elements”.

Furthermore, in a coupled condition of two of said adjacent floorelements, the coupling elements cooperate and preferably form lockingsurfaces limiting the mutual movement of said floor elements in verticaland/or one or more horizontal directions. Preferably, in a coupledcondition of two adjacent floor elements, first locking surfaces areformed limiting the mutual movement of said floor elements in adirection perpendicular to the coupled edges and in a substantiallyhorizontal plane. Furthermore, in said coupled condition, second lockingsurfaces are formed limiting the mutual movement of said floor elementsin a substantially vertical direction. Due to this solution, the floorelements can fluently be installed without the occurrence ofunacceptable height differences between adjacent floor elements.Moreover, the floor elements are solidly coupled to each other toimprove the fatigue behavior of the floor covering. Further, by limitingrelative movement of the floor element, it is possible to reduce thestep noise effect, i.e. reduce the noise generated at every step.

According to a preferred embodiment of the invention, the male part andfemale part can be disposed substantially along the whole length of therelated edge, for example, substantially defining the related edge. Forexample, according to this embodiment, the male and the female parts,can be basically shaped as a tongue and a groove that substantially runthrough the whole length of the related mutually opposite edges.Preferably, the male part is positioned at a first edge of the floorelement and at least the female part is positioned at a second oppositeedge of the floor element.

Alternatively, the male part and the female part may extend over alimited length portion of the related edge, wherein such limited lengthis smaller than the whole length of the related edge itself, preferablysmaller than half the length of the related edge. In accordance withthis possibility, the edges preferably comprise sections free from saidmale part and said female parts. Geometries for coupling parts inaccordance with this alternative embodiment include cooperating male andfemale parts which in a top plan view are dovetail-shaped or male andfemale parts which in a top plan view resemble the connections of jigsawpuzzles.

In some embodiments the coupling elements are configured so that, in acoupled condition, a pretensioned state is established between thecoupling element. In other words, the coupling element are configured sothat in the coupled condition they are elastically deformed therebyexerting a counter reaction each-other. Due to this solution thecoupling between the floor element is strengthened and the couplingitself helps the waterproofing of the floor covering. According to apreferred embodiment of the invention the coupling elements areconfigured so that, in a coupled condition, the coupling is free frompretension so that the coupling is simplified, and a lower force needsto be exerted by the operator. That is to say that, in the coupledcondition the coupling elements are in an undeformed condition.Moreover, also the coupling movement of the coupling element, i.e. therelative movement between the coupling elements that allows themechanical coupling, occurs without deformation of the couplingelements. For example, in some embodiments a play is established betweenthe coupling elements in the coupled position so that tiny movementsbetween the coupling elements in a vertical and/or horizontal directionare admitted. For example, the dimension of the male part on a planeorthogonal to the respective edge is equal or slightly smaller than thedimension of the female part on the same plane.

The coupling elements are configured to allow realizing a coupling bymeans of a movement of one floor element with respect to anotheradjacent floor element. Such movement may be a translational motion in adownward, e.g. vertical, direction, a translational motion in ahorizontal direction, e.g. perpendicular to the edges or an anglingmotion around a horizontal axis parallel to the edges. It is clear thatthe respective motion then preferably results in the aforementioned maleand female parts of adjacent floor elements becoming mutually engaged.

Thereto, the coupling elements may be construed in accordance withseveral different possibilities, of which here below two are shortlydescribed.

According to a first possibility, said coupling elements are configuredfor being coupled each other by means of an angling motion around ahorizontal axis parallel to the edges. According this first possibility,it is also preferred that the coupling element are configured for beingcoupled by means of a translational motion in a horizontal direction,e.g. perpendicular to the edge. According to said first possibility themale and female parts are respectively shaped in form of tongue andgroove, wherein the tongue projects outwardly beyond its respective edgein a horizontal direction and the groove projects inwardly with respectto the respective edge in a horizontal direction. As already indicatedabove the tongue and the groove are configured in such a way that in acoupled condition of said tongue and groove the first and second lockingsurfaces are formed to limit relative movements of the floor elements invertical and horizontal direction, and wherein said horizontal directionis perpendicular to the edge. According to a preferred embodiment, thetongue comprises a horizontal extending lip and a downward projectinghump. As a consequence, in this embodiment, the groove has a horizontalrecess, for receiving the lip of the tongue, and an upward orientedhollow portion, for receiving the hump of the tongue, so that tongue canbe fitted into the groove. It is also preferred that in a coupledcondition the tongue fits into the groove in such a way that ahorizontal inoperative space is established between the tip of thetongue, in particular of the lip thereof, and the bottom of the groove,in particular of the recess thereof. It is also preferred that in acoupled condition the tongue fits into the groove in such a way that avertical inoperative space is established is established between thelower surface of the tongue, in particular of the lip thereof, and thegroove, in particular the recess thereof. Due to this solution there isprovided a tongue having a lip narrower that the groove so that theangling movement for coupling the floor elements is definitely improved.It is also preferred that in the coupled condition the downwardprojecting hump of the tongue contacts the hollow portion of the groove,and the upper surface of the tongue contacts the groove. In particular,it is preferred that the lower surface of the tongue contacts the grooveonly in correspondence of the hump. Due to this said second contactsurfaces for preventing the vertical mutual movement of the floorelement are provided, while coupling by angling movement is simplifiedbecause the lower contact is formed only in correspondence of the humpof the tongue and not of the lip thereof.

Moreover, according to a preferred embodiment of this first possibility,in the coupled condition of the tongue and the groove is formed a play.Said play allows tiny movements in a vertical and/or horizontaldirection, preferably in the horizontal direction. The play is such thatthe tongue and the groove can be coupled each other without beingdeformed.

As a consequence of this, the effort exerted by the operator who wantsto install the floor elements is significantly reduced, this isparticularly important since the weight of the decorative layer if onone hand complicates the installation operations, on the other handshelps the locking between the floor elements. Therefore, a slightlyslack coupling due to the play is admitted and helpful for improving theeasiness of installation. Preferably, said play is greater than 0.01 mm,preferably greater than 0.03 mm. Moreover, said play is preferably lessthan 0.10 mm, for example less than 0.08 mm.

According to a second possibility, said coupling elements are configuredfor being coupled by means of a translational motion in a downward, e.g.vertical, direction. According to this second possibility the couplingelements comprise an upward-directed lower hook-shaped part which issituated on one edge, as well as a downward-directed upper hook-shapedpart, which is situated on the opposite edge. Lower hook-shaped partdefines an upward directed cavity forming a female part, whereas theupper hook-shaped part defines a downward-directed lip forming a malepart. Once in a coupled position the downward-directed lip and theupward-directed cavity form the first locking surface for limitingmutual movement in a horizontal direction, e.g. perpendicular to theedge. Preferably the upper hook-shaped part and the lower hook shapedpart, more preferably respectively the lip and the cavity, areconfigured so that in the coupled condition the second locking surfaceare formed to limit the mutual movement of the floor elements in thevertical direction. More particularly, the upper hook-shaped part andthe lower hook shaped part are configured so that two sets of saidsecond locking surfaces are formed, for example on opposite of the malepart and the female part. Preferably, both the upper hook-shaped partand the lower hook shaped part comprise undercut portions so that in thecoupled condition the first and/or the second locking surfaces areformed to limit the mutual movement of the floor elements. Moreover, thecoupling elements according to said second possibility are configured tobe deformed during the coupling movement. Preferably, the lower hookshaped part comprises a flexible lever portion configured to be deformedby the coupling off the upper hook-shaped part lower hook shaped part sothat by means of said deformation it is possible the coupling of theundercut portions.

It is noted that the floor element may comprise the same couplingelements, i.e. according to the first or to the second possibility, onall its edges. According to a preferred embodiment of the invention, thefloor element can comprise coupling elements of different shape or ofdifferent dimension on different edges. For example, a floor element cancomprise coupling elements according to the first possibility on a firstcouple of opposite edges, e.g. in case of rectangular floor element thelong edges, and coupling elements according to the second possibility ona second couple of opposite edges, e.g. the short edges. In other words,a rectangular floor element can comprise coupling elements adapted forbeing coupled by means of an angling movement on the long edges andcoupling elements adapted for being coupled by means of a translationalmotion in a downward direction on the short edges. Due to this solution,the coupling between the floor elements is significantly simplified. Infact, due to the angling movement, for example provided by the tongueand groove, it is easy to align the long edges of the floor elementsthereby simplifying the positioning and providing a strong coupling inboth vertical and horizontal direction between the long edge, while theshort edges can be easily coupled by means of a translational motion ina downward direction as a direct consequence of the coupling between thelong edges. This can be particularly advantageous in case of a heavydecorative layers, in fact once the coupling elements according to thefirst possibility, e.g. the tongue and the groove on the long sides, arecoupled it is sufficient to let the floor element lay in the horizontalposition to realize the mechanical coupling of the coupling elementsaccording to the second possibility, e.g. on the short edges without theneed of hammering or beating the floor element itself. This happens alsoin case the coupling elements according to the second possibility aredeformed during the coupling since the weight of the decorative layermay be sufficient to cause said deformation.

Preferably, the support layer has a shape basically corresponding to thedecorative layer, however, preferably, with one or more portionsextending beyond the decorative layer. The support layer may alsocomprise one or more recesses extending underneath the decorative layer.The support layer preferably is a coherent element, wherein the supportlayer preferably covers the majority, i.e. at least 50 percent, of thelower surface of said decorative layer. Preferably the support layercovers 80 percent or more of the lower surface of the decorative layer.According to another embodiment, the support layer comprises a pluralityof separate adjacent support layer portions, in which case saidplurality of support layer portions preferably covers at least 50percent of the lower surface, or even 80 percent or more thereof.

The floor element may comprise any dimension, although it is preferredthat it comprises a superficial area of less than 1.5 sqm, preferablyless than 1 sqm, more preferably less than 0.4 sqm. For example, thefloor element, and in particular the decorative layer, comprises an edgehaving a maximum length of less than 1.5 m, preferably less than 0.9 m.In fact, the floor elements are destined to lay on a subfloor that mayhave irregularities like depressions or bumps that can affect the floorcovering installation, the impact resistance and also the fatigueresistance of the floor elements. For floor elements having a reducedarea it is reduced the effect of said irregularities as well as theprobability of encounter said irregularities. Moreover, the decorativelayer, especially in the case that is made of a ceramic material, may beslightly bowed so that there may be the same issues due toirregularities of the subfloor. The larger the side of the decorativelayer is, the larger said bending is so that is preferred that the floorelement, and the decorative layer, comprise a reduced superficial area.

In a coupled condition of two of said floor elements preferably anintermediate distance is available between the respective upper edges ofadjacent floor elements. Preferably, the decorative layer is mounted onthe support layer in such a way that when the floor elements are in acoupled condition said intermediate distance is available between theedges of adjacent decorative layers, while the edges of the underlyingsupport layer are coupled to each other by means of the availablecoupling elements. Due to this solution slight dimensional variations ofthe decorative layer of adjacent tiles may be tolerated. In the caseswhere the decorative layer is formed by one or more ceramic tiles, bothunrectified tiles and rectified tiles may be selected, whereinunrectified tiles are preferred since they are less expensive than therectified ones. Even when rectified tiles would be selected, anintermediate distance of at least 1.5 millimeter, for example around 3millimeters or more is preferred in case of unrectified tiles. Ingeneral, with brittle decorative layers, direct contact between theedges of the decorative layers of adjacent floor elements is best to beprevented in order to minimize the risk of breaking off edge portionsupon installation, or upon use of the floor covering. The prevention ofdirect contact between the edges of the decorative layers also preventssqueaking noises from generating when the floor is walked upon. Furthersome decorative layers and/or support layers may expand or contract dueto thermal variation. The available intermediate distance prevents thatsuch expansion and contraction affect the stability of the floor. Forexample, the decorative layer can be mounted on the support layer insuch a way that is centered onto an upper surface of the support layer,e.g. each upper edge of the support layer extends beyond the edge of thedecorative layer of the same predetermined distance. For example, saidpredetermined distance can be half of the intermediate distance betweenthe respective upper edges of adjacent floor elements in the coupledcondition. This solution is especially preferred in case unrectifiedtiles are used because it often simplifies the positioning of tiles thatmay have slightly different dimensions on support layers having the samedimensions.

The intermediate distance, or gap, between the decorative layers ofadjacent floor elements can be further finished in several possibleways.

According to a first possibility, said intermediate distance between thefloor elements can be filled by a grout thereby providing an impermeablefloor covering. Preferably a polymeric and/or cement-based grout isused. The grout may be a flexible or rigid grout. A flexible grout maybe for example a silicone-based grout whereas a rigid grout may be forexample an epoxy-based grout or cement-based grout.

In a second possibility, the decorative layer can be at least partially,preferably completely, surrounded by a gasket so that in a coupledcondition of two adjacent floor elements said gasket is compressed bythe decorative layer of an adjacent floor element so to form asubstantially water tight connection between the floor elements.

It is noted that the characteristic that the floor element comprises anintermediate layer having a resin material that permeates a lowersurface of the decorative layer, forms an inventive idea irrespective ofthe presence of a support layer, and in particular of a support layercomprising edges with coupling elements configured to realize amechanical coupling with coupling elements of an adjacent floor element.Hence, the present invention, according to a second independent aspect,relates to a floor element for forming a floor covering, wherein thisfloor element comprises a first decorative layer made of a ceramicmaterial and a second layer arranged below this decorative layer,wherein the second comprises a resin material that permeates a lowersurface of the decorative layer. According to this second independentaspect of the invention the floor element may optionally comprise athird support layer placed below the second layer. Moreover, optionallysaid third support layer may comprise one or more of the features of thesupport layer described above in relation to the first independentaspect. It is clear that also the decorative layer and the intermediatelayer may comprise one or more of the features described above inrelation to the first independent aspect.

As an example, a floor element according to said second independentaspect may be installed on a subfloor by means of a pressure sensitiveadhesive layer, a tack fast loop fabric layer, (for example Velcro®).For example, the floor element may comprise a pressure sensitiveadhesive layer placed below the second layer, for example a bi-adhesivelayer covered by a covering sheet to be peeled out before installing thefloor element onto the subfloor. Alternatively, the floor element mayalso be installed on a pressure sensitive adhesive underlayment. As afurther example a floor element according to said second independentaspect may be installed on a subfloor by means of a tack fast loopfabric layer (for example Velcro®). In this case the floor element maycomprise a third support layer comprising a loop and hook fabric adaptedto interlock with an underlayment of the subfloor. Moreover, forexample, the floor element according to said second independent aspectmay be installed on a subfloor by means of magnetic means. In this casethe, floor element may comprise a third support layer comprising amagnetic and/or ferromagnetic material suitable to interact with amagnetic and/or ferromagnetic underlayment of the subfloor.

It is to be noted that the fact that the resin material may be used forforming a floor covering comprising a decorative layer, for example madeof a ceramic material, and wherein the resin permeates a lower surfaceof the decorative layer, forms an inventive idea irrespective of thefurther characteristic of the floor element like, by way of example, thenature of the decorative layer and the presence of the support layer.Hence, for example, according to a third independent aspect, theinvention relates to a use of a resin material for bonding together adecorative layer made of a ceramic material and a support layer to forma floor element. Wherein the resin material may comprise one or more ofthe features of the support layer described above in relation to thefirst independent aspect. Also, the decorative layer and the supportlayer may comprise one or more of the features described above inrelation to the first independent aspect.

According to a fourth independent aspect of the invention, it isprovided a floor covering comprising a plurality of adjacent floorelements, wherein each floor element comprises a decorative layer ofceramic material and a support layer disposed below the decorativelayer, wherein the floor covering comprises the combination of thefollowing features: at least one floor element comprises a intermediatelayer having a resin material that permeates a lower surface of thedecorative layer; the floor elements comprise coupling elementsconfigured to realize a coupling with coupling elements of adjacentfloor elements; the floor covering comprises a grout filling anintermediate distance separating the decorative layers of the floorelements. Preferably the floor elements are separated from a subsurface,for example the subfloor, i.e. they are not bonded to the subsurface bymeans of adhesive or mechanical means. Due to this solution is provideda floor covering composed of floor elements installed without using ofadhesive, that shows a high satisfying impact and fatigue strength, andis totally impermeable. By means of the second aspect, the inventorshave finally offered a solution to a long-felt need in the ceramicflooring world. They have provided an easy to be installed ceramic tileflooring, with a good impact strength and waterproofness. It is clearthat the floor elements of the first aspect, and preferred embodimentsthereof, may be used to form a floor covering in accordance with thepresent third aspect.

According to a preferred embodiment of the invention the floor coveringcomprises an under-layer disposed beneath the floor elements that isconfigured to act as a moisture barrier. Due to this solution it ispossible to prevent the forming of mold underneath the floor elements.In combination or as an alternative to this solution, the under-layercan be configured to act as a noise barrier thereby reducing the noisegenerated by steps on the floor.

The invention further relates to a a method for manufacturing the floorelement, for example the floor element of the present invention.Therefore, according to a fifth independent aspect of the invention itis provided a method for manufacturing a floor element comprising thesteps of: providing a decorative layer made of a ceramic material;providing a support layer; providing a resin material for bonding thedecorative layer and the support layer together; pressing the layerstogether for forming the floor element such that the resin materialpermeates the ceramic layer. In this way it is provided a method thatallows manufacturing of floor elements to be installed on a subfloorwithout glue or adhesive and that shows relevant impact and fatigueresistance. Moreover, said method allows the manufacturing of highresistance floor elements in a simple and effective way. In fact, sinceit is not necessary the use of rigid reinforcing element, the methodcomprise a reduced number of steps so that it is relatively quick, andit can be carried out by means of a relative simple equipment. It isclear that the obtained floor element preferably shows thecharacteristic of the previously described floor elements of theinvention.

The step of providing the decorative layer may comprise a step ofbrushing and/or roughing the lower surface of the decorative. Said stepof brushing and/or roughing has the goal of prepare the lower surface ofthe decorative layer to be permeated by the resin material. For example,in case the decorative layer is made of a ceramic material, said step ofbrushing and/or roughing aims to remove the backwash and/or thestructure of the lower surface of the decorative layer. In this way, anydecorative layer may be used for manufacturing the floor element withoutbeing necessary to manufacture a specific decorative layer for the floorelement, for example without being necessary to manufacture a ceramictile without the backwash and without the structure on the lowersurface.

As already described, the support layer may comprise edges provided withcoupling elements. Therefore, according to a preferred embodiment of theinvention, the step of providing the support layer may comprise the stepof providing a support layer comprising edges provided with couplingelements, i.e. the coupling elements are provided in the support layerduring a separate process. Alternatively, the method for manufacturingthe floor element may comprise a step of providing the coupling elementsin the edges of the support layer. Said step of providing the couplingelements may comprising milling, molding or other techniques. Moreover,said step of providing the coupling elements may be conducted eitherbefore or after a step of placing the decorative layer above the supportlayer, for example either before said step of providing the resin orafter said step of pressing.

The step of providing the resin comprises the step of applying anon-cured resin on at least a surface of the decorative layer and/or ofthe support layer. The resin material may be provided by means ofrolling, spraying, curtain or other techniques. According to anembodiment of the invention the resin material is applied onto the uppersurface of the support layer. According to an alternative embodiment theresin material is applied during multiple intermediate steps, forexample a first amount of resin is applied onto the upper surface of thesupport layer in a first intermediate step and a second amount of resinis applied onto the lower surface of the decorative layer in a secondintermediate step. This solution is preferred especially formanufacturing floor elements wherein the intermediate layer comprises areinforcing element, for example a fiber. In fact, in this case a higheramount of resin may be necessary and multiple steps for providing theresin may be ideal to ensure the correct gluing between the layers,embedding of the reinforcing element and permeation of the decorativelayer.

The step of providing the resin can comprise the step of mixing thecomponents thereof, in case the resin is a bicomponent resin, forexample a bicomponent epoxy. Said step of mixing may be executed during,i.e. contemporarily, or shortly before the step of applying the uncuredresin. In fact, often the curing of the resin is activated by the mixingof its components and as a consequence the viscosity of the resinincreases. Thus, it is preferable to delay as much as possible the startof the curing reaction in order to make easier to spread the resin ontothe layers' surfaces and improve the permeation of the decorative layer.For example, according to a preferred embodiment of the invention, theresin is applied by means of spraying and the components are mixedduring spraying, for example substantially in correspondence of a nozzleof the spray equipment.

Preferably, during the pressing step it is exerted onto the layers apressure of at least 350 kg/sqm, more preferably at least 370 kg/sqm.Said values have been found optimal to make the resin permeating thedecorative layer. Moreover, these values have been found optimal forallowing the resin to reach a 100% coverage of the lower surface of thedecorative layer, because in certain embodiment the resin is appliedaccording to a pattern and then spread during said pressing step.Moreover, the inventors have found that by keeping the pressure for aprolonged pressing time it is possible to improve the permeation of thedecorative layer, for example it is possible to obtain a higherpenetration depth. Therefore, according to a preferred aspect of theinvention the during the pressing step, the pressure is kept for apressing time of more than 1 second, preferably more than 10 seconds,for example 30 seconds. This pressing time have been found optimal forallowing the resin to reach a 100% coverage of the lower surface of thedecorative layer in case the resin is applied according to a pattern.Moreover, especially in case of resin made of epoxy, said pressing timeis sufficient for making the resin to start curing so that thedecorative layer and the support layer at least partially adhere eachother and sliding between them during transportation of the floorelements after pressing are prevented.

The step of pressing may be conducted in any suitable way for applying apressure to the decorative layer and/or the support layer in order tohelp the resin penetrating the decorative layer. Therefore, according toan embodiment of the invention the step of pressing may be a staticpressing step wherein the layers enters into a mold of a static press sothat is subjected to a predetermined pressure by means of a punch of thepress. In this way it is possible to keep the pressure for thepredetermined pressing time to improve the permeation of the decorativelayer. According to an alternative embodiment the step of pressing maybe a lamination step wherein the layers runs into a laminatingequipment, for example under one laminating roller or belt, or between acouple of laminating rollers, so that is subjected to a predeterminedpressure. Since lamination is a continuous process it is possible tospeed up the global manufacturing method while at the same time exertinga sufficient pressure onto the layers for the permeation of thedecorative layer. During lamination the pressing time is function of theadvancing speed of the layers, therefore the advancing speed may beregulated in order to speed up the process while at the same time asufficient pressing time is guaranteed.

Preferably, the method comprises a step of stocking the floor elementsfor a stocking time in order to allow the resin to at least partiallycure before being, packaged, transported and/or used in a floorcovering. Preferably the stocking time is such to allow the resin to beat least 70% cured, preferably 85% cured, more preferably fully cured.For example, said stocking time is at least 0.5 h, preferably more than1 h, for example 2 h.

It is also further noted that the characteristic that a floor elementcan comprise coupling elements according to the first possibility on afirst couple of opposite edges, and coupling elements according to thesecond possibility on a second couple of opposite edges, forms anindependent inventive concept irrespective from other features of thefloor element. Therefore, according to a sixth independent aspect theinvention relates to a floor element comprising a decorative layer madeof a ceramic material, and a support layer arranged below the decorativelayer, wherein the support layer comprises at least two couples ofopposite edges which comprise coupling elements configured to realize amechanical coupling with coupling elements of adjacent floor elements,wherein first coupling elements at a first couple of edges areconfigured for being coupled to the coupling elements of adjacent floorelements by means of an angling motion around a horizontal axis parallelto the respective edges, and wherein second coupling elements at asecond couple of edges are configured for being coupled to the couplingelements of adjacent floor elements by means of an translationaldownward direction of the respective edges towards each other. Thiscombination of different typologies of coupling elements is particularlyadvantageous in case of a heavy decorative layers, like ceramic stonesor the like, in fact once the first coupling elements are coupled it issufficient to let the floor element lay in the horizontal position torealize the mechanical coupling of the second coupling elements withoutthe need of hammering or beating the floor element itself. This happensalso in case the second coupling elements are deformed during thecoupling since the weight of the decorative layer may be sufficient tocause said deformation. Once the first coupling elements are connected,the user can have the impression of simply dropping off the floorelements for completing the coupling since no more effort is required.It is noted that the floor element according to the sixth independentaspect may comprise one or more of the features described in relation tothe first independent aspect.

It is noted, within the scope of this sixth independent aspect, apreferred embodiment comprises a decorative layer made of ceramichowever, it is noted that this sixth aspect can be advantageouslyapplied with decorative layers being made of any kind of relativelyheavy material, such as natural stone, quartz, artificial stone,concrete, glass or glass-ceramic material. It is also noted that thissixth aspect can be advantageously applied with decorative layers havingdensity as expressed by surface weight of at least 10 kg/sqm, preferablygreater than 15 kg/sqm, for example greater than 19 kg/sqm, irrespectiveof the material forming the decorative layer.

The inventors have also found that the coupling of floor elementsaccording to the sixth independent aspect is further simplified if inthe coupled condition the first coupling elements are connected withplay, for example a horizontal play. In fact, if on one hand the weightof the decorative layer simplifies the coupling of the second couplingelements once the first coupling elements are coupled, on the other handit complicates said coupling of the first coupling elements, and inparticular it complicates the maneuverability of the floor element.Therefore, the play helps said coupling at the first couple of edges.This effect is further enhanced if the play is larger than play isgreater than 0.01 mm, preferably greater than 0.03 mm. Moreover, saidplay is preferably less than 0.10 mm, for example less than 0.08 mm. Inparticular, this effect is further enhanced if the play is such that thefirst coupling elements may be coupled to each other without beingdeformed.

FIG. 1 shows a top view of an embodiment of a floor element 1 accordingto the invention. The floor element 1 comprises a decorative layer 2disposed above a support layer 3.

As illustrated, the floor element 1 comprises a rectangular elongatedshape. Preferably, the floor element 1 comprises a superficial area ofless than 1.5 sqm, preferably less than 1 sqm, more preferably less than0.4 sqm. For example, the decorative layer 2 comprises edges having amaximum length L of less than 1.5 m, preferably less than 0.9 m.

The decorative layer 1 has an upper face 4 comprising a décor 5. Thedécor 5 can be provided with a variety of textures, designs and colors.In the illustrated example the décor simulates a wood pattern comprisingwood nerves and flakes. Preferably, the décor 5 is at least partiallyformed by a print 6. The print 6 is preferably realized by means ofdigital printing, such as inkjet printing, although screen printing,rotogravure, flexography or off-set printing is not excluded.

FIG. 2 on a larger scale shows a cross section along the line II-II ofFIG. 1. According to the illustrated example the decorative layer 2comprises a body 7 made of a ceramic material, for example red bodyceramic or porcelain.

The decorative layer 2 comprises a background coating 8 covering atleast partially the upper surface of the body 7, for example comprisingat least a glaze. The background coating 8 is adapted to receive thedécor 5 on its top, for example adapted to receive the print 6 on itstop. The background coating 8 can be white, beige, brown or of any colorsuitable to receive the décor 7 on its top.

The decorative layer 2 further comprises a protective coating 9 coveringat least partially the upper surface of the body 7, for examplecomprising at least a glaze. The protective coating 9 is adapted to beplaced above the décor 5 and is transparent or translucent.

FIG. 2 also shows that decorative layer 2 has a thickness T1 comprisedbetween 4 and 15 mm, for example 6 mm, preferably greater than 7 mm, forexample 8 or 10 mm.

The support layer 3, according to the example, is made of a polymericmaterial, preferably a thermoplastic material like PVC. In a preferredembodiment, the support layer is made of a rigid PVC. Within the contextof the present description, “rigid” means that the support layer, takenalone, bends under the own weight thereof less than 10 cm per meter andstill better less than 5 cm per meter. The support layer 3 may alsocomprise a high amount of filler materials, such as chalk, e.g. morethan 30 wt % or more than 60% wt of such filler materials.

Moreover, according to a preferred embodiment, the support layer 3 ismade of a rigid PVC that may comprise a flexural modulus between 1.5 and3.5 GPa, for example, approximately 2.6 GPa. The support layer 3 mayalso comprise a flexural strength between 60 and 90 MPa, for exampleapproximately 76 MPa. Moreover, the support layer 3 may comprise acompressive strength between 40 and 70 MPa, for example approximately 56MPa.

Furthermore, the support layer 3 preferably has a thickness T2 comprisedbetween 2 and 7 mm, preferably less than 6 mm, more preferably about 4mm or less.

FIG. 2 also shows that the support layer 3 comprises longitudinal edges10 provided with first coupling elements 11,12 configured to realize amechanical coupling with coupling elements 11,12 of an adjacent floorelement 1. In the illustrated examples the coupling elements 11,12comprise a male and female parts disposed on opposite longitudinal edges10.

The first coupling elements 11,12 of the longitudinal edges 10 areconfigured for being coupled each other by means of an angling motionaround a horizontal axis parallel to the longitudinal edges 10. The maleand female parts are respectively shaped in form of a tongue 11 and agroove 12 wherein the tongue 11 projects outwardly beyond its respectivelongitudinal edge 10 in a horizontal direction X and the groove 12projects inwardly with respect to the respective longitudinal edge 10 insaid horizontal direction.

The support layer 3 extends beyond longitudinal edges 26 of thedecorative layer 2. In the example, the support layer 3 comprises upperlongitudinal edges 27 that extend beyond the longitudinal edge 26 of thedecorative layer 2 of a distance D1. Said distance D1 is equal on boththe opposite longitudinal edges 26 of the decorative layer 2.

FIG. 2 further shows that the floor element 1 comprises an intermediatelayer 13 disposed between the decorative layer 2 and the support layer3. The intermediate layer 13 comprises a resin material, for example athermosetting resin or thermoplastic resin. Examples of thermosettingresin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examplesof thermoplastic resin are hot melt, polyester thermoplastic, vinyl etc.Preferably the resin is a rigid resin. In particular, according to apreferred embodiment of the invention the intermediate layer comprisesan epoxy resin. It is also preferred that the epoxy is a bicomponentresin, i.e. a thermosetting resin obtained by curing at low temperature(for example at room temperature) a mixture of two components, namely aresin and a hardener.

The resin preferably comprises a tensile strength between 50 and 90 MPa,more preferably between 60 and 80 MPa, for example 75 MPa. Moreover, theresin preferably comprises a compressive strength between 90 and 130MPa, more preferably between 100 and 120 MPa, for example 110 MPa. It isalso preferable that the resin shows a hardness value of at least 50measured on a Shore D scale.

As illustrated the intermediate layer 13 covers the 100 percent of thelower surface of the decorative layer 2. The resin is preferablyprovided onto the lower surface of the decorative layer 2 in an amountgreater than 150 g/sqm, more preferably greater than 200 g/sqm, forexample 220 g/sqm.

In the preferred example illustrated in FIG. 2, the intermediate layer13 is in direct contact with the upper surface of the support layer 3 sothat act as a glue between the decorative layer 2 and the support layer3.

FIG. 3 on a larger scale shows a view on the area F3 indicated on FIG.2. As illustrated in FIG. 3 the decorative layer 2, more in detail thebody 7 thereof, comprises, at least in correspondence of its lowersurface, an open porosity 14 adapted permeated by the resin of thedecorative layer 2 itself.

Thus, according to a preferred embodiment of the invention thedecorative layer 2 comprises an apparent porosity between 0.1% and 10%determined according to ASTM C373, more preferably between 2% and 8%,for example 6%. Furthermore, the decorative layer may preferably have avolume of the open pores 14 comprised between 0.01 cc (cubic centimeter)and 1 cc, more preferably between 0.10 cc and 0.90 cc, for example 0.60cc.

Therefore, in order to properly flow into said open pores 14 the resincomprises a viscosity at 20° C. less than 1000 Pas, preferably less than800 Pas, more preferably less than 600 Pas, for example approximately400 Pas. Within the scope of the invention viscosity means the viscosityof the uncured resin, for example the viscosity of the mixture of thetwo components before the completion of the curing, i.e. during theso-called pot life.

FIG. 4 shows on a larger scale shows a cross section along the lineIv-Iv of FIG. 1. According to the embodiment the support layer 3comprises transversal edges 15 provided with second coupling elements16, 17 configured to realize a mechanical coupling with second couplingelements 16, 17 of an adjacent floor element 1.

In the illustrated examples the second coupling elements 16, 17 aredifferent from the first coupling elements 11, 12 of the longitudinaledges 10. The second coupling elements 16, 17 of the transversal edges15 are configured for being coupled each other by means of atranslational movement along a substantially vertical direction. In theillustrated examples, said second coupling element 16, 17 are configuredfor being coupled by means of a translational motion in a downward, e.g.vertical, direction Y.

The support layer 3 extends beyond transversal edges 28 of thedecorative layer 2. In the example, the support layer 3 comprises uppertransversal edges 29 that extend beyond the transversal edge 28 of thedecorative layer 2 of a distance D2. Said distance D2 is equal on boththe opposite edges 28 of the decorative layer 2. Moreover, in saidpreferred example, said distance D2 is equal to the distance D1.

FIG. 5 is a top plane view of a floor covering 18 comprising a pluralityof floor elements 1 coupled by means of the first coupling elements11,12 along the longitudinal edges 10 and by means of the secondcoupling elements 16,17 along the transversal edges 15.

FIG. 6 on a larger scale shows a cross section along the line VI-VI ofFIG. 5. The floor covering 18 comprises a grout 19 filling anintermediate distance I separating the decorative layers 2 of the floorelements 1. According to the illustrated example, the intermediatedistance I is twice the distance D1 between the upper edge of thesupport layer 3 and the edge of the decorative layer 3.

The grout 19 is preferably made of a polymeric material. The grout 19may be a flexible or rigid grout. A flexible grout 19 may be for examplea silicone-based grout whereas a rigid grout may be for example anepoxy-based grout or cement-based grout.

FIG. 6 further shows a section of the mechanical coupling between thefirsts coupling elements 11,12 along a plane transversal to thelongitudinal edges 10. Said mechanical coupling between the firstscoupling elements 11,12 is described in detail with the aid of FIG. 7.

FIG. 7 on a larger scale shows a view on the area F7 indicated on FIG.6. According to the example illustrated in FIG. 7, the tongue 11comprises a horizontal extending lip 20 and a downward projecting hump21. The groove 12 has a horizontal recess 22, for receiving the lip 20of the tongue 11, and an upward oriented hollow portion 23, forreceiving the hump 21 of the tongue 11, so that tongue 11 can be fittedinto the groove 12.

In the coupled condition shown in FIG. 7 the upper edges 27 of thesupport layers 3 contact each other thereby forming a first set of firstlocking surfaces 24 limiting the mutual movement of said floor elements1 in a horizontal direction X perpendicular to the coupled longitudinaledges 10.

FIG. 7 also shows that in said coupled condition, the lip 20 is receivedby the recess 22. The upper surface of the lip 20 contacts un upper wallof the recess 22 thereby forming a first set of second locking surfaces25 are formed limiting the mutual movement of said floor elements 1 in asubstantially vertical direction Y. It is noted that between the tip ofthe lip 20 and the bottom of the recess 22 is established a horizontalinoperative space S1. Moreover, between lower surface of the lip 20 andthe recess 22 is established a vertical inoperative space S2.

The downward projecting hump 21 of the tongue 11 is received by thehollow portion 23 of the groove 12. The lower surface of the downwardprojecting hump 21 contacts said hollow portion 23 so that a second setof second locking surfaces 25 is formed. In other words, the lowersurface of the tongue 16 contacts the groove 12 exclusively incorrespondence of the downward projecting hump 21.

In the coupled condition, of FIG. 7, between the projecting hump 21 andthe hollow portion 23 is formed a horizontal play P that allows tinyhorizontal movement of the tongue 11 into the groove 12. Said play P andsaid tiny horizontal movements are limited by a set of first contactsurface that may be formed between the projecting hump 21 and the hollowportion 23.

Preferably, said play P is larger than 0.01 mm, preferably larger than0.03 mm. Moreover, said play P is preferably smaller than 0.10 mm, forexample smaller than 0.08 mm.

It is noted that in the coupled condition the tongue 11 and the groove12 are in an undeformed condition. Further, the whole angling movementthat allows the coupling between the tongue 11 and the groove 12 occurwithout deformation of the first coupling elements 11,12. In fact due tothe play P and the inoperative spaces S1, S2 the coupling between thetongue 11 and the groove 12 is significantly simplified.

FIG. 8 on a larger scale shows a cross section along the line VIII-VIIIof FIG. 5. FIG. 8 shows a section of the mechanical coupling between thesecond coupling elements 16,17 along a plane transversal to thetransversal edges 15. Said mechanical coupling between the secondcoupling elements 16,17 is described in detail with the aid of FIG. 9.

FIG. 9 on a larger scale shows a view on the area F9 indicated on FIG.8.

The second coupling element elements 16,17 comprise downward-directedupper hook-shaped part 16 is situated on one transversal edge 15 and dupward-directed lower hook-shaped part 17, which is situated on theopposite edge 15. The lower hook-shaped part 17 defines an upwarddirected cavity forming a female part, whereas the upper hook-shapedpart 16 defines a downward-directed lip forming a male part.

Once in a coupled position the downward-directed lip and theupward-directed cavity form the first locking surface 24 for limitingmutual movement of the floor elements 1 in a horizontal direction Zperpendicular to the transversal edge 15.

Moreover, both the upper hook-shaped part 16 and the lower hook shapedpart 17 comprise undercut 30 portions so that in the coupled conditionthe second locking surfaces 25 are formed to limit the mutual movementof the floor elements 1 in the vertical direction Y. More in particular,two sets of said second locking surfaces 25 are formed, for example onopposite sides of the male part and the female part.

Preferably, the lower hook shaped part 17 comprise a flexible leverportion 31 configured to be deformed by the coupling off the upperhook-shaped part 16 lower hook shaped part 17 so that by means of saiddeformation it is possible the coupling of the undercut portions 30.

FIG. 10 shows some steps of a method for manufacturing a floor element.The method comprises a first step S1 of providing the decorative layer2. In the step S1 the decorative layer 2 is provided into a resinapplication station 40 wherein the uncured resin material R is provided,for example according to a pattern, onto a lower surface of thedecorative layer 2. The uncured resin R preferably comprises a viscosityat 20° C. lower than 1000 Pas, preferably less than 800 Pas, morepreferably less than 600 Pas, for example approximately 400 Pas. It isnoted that in the resin application station 40 the decorative layer isplaced with the upper surface, comprising the décor 6, facing down.

Then, in a step S2 the decorative layer 2 is carried into a placingstation 41 wherein the support layer 3 is provided. The support layer 2is placed below the lower surface decorative layer 3 thereby forming asemi-finished sandwich 42. Preferably, in said placing station 41 thedecorative layer 2 and the support layer 2 are properly centeredrelative to each other.

Successively, in a step S3 the semi-finished sandwich 42 is carried intoa pressing station 43 wherein the layers 2,3 are pressed together forforming the floor element 1 such that the resin material permeates thepores of the ceramic material of the decorative layer 2 and forms theintermediate layer 13. Preferably, the pressure is kept for a pressingtime of at least 1 second, preferably 30 seconds so that the uncuredresin R can flow covering, at least the 80%, preferably the 100% of thelower surface of the decorative layer 2. Moreover, said pressing time isnecessary to let the uncured resin R permeates the decorative layer 2.Preferably, during step S4 it is exerted onto the layers a pressure ofat least 350 kg/sqm.

Then in a step S4 pressed floor element 1 is then carried into astocking station 44 wherein for a predetermined stocking time in orderto allow the resin R to continue curing before being, packaged,transported and/or used in a floor covering. Preferably the stockingtime is such to allow the resin R to be at least 70% cured, preferably85% cured, more preferably fully cured. For example, said stocking timeis at least 0.5 h, preferably more than 1 h, for example 2 h.

The present invention is in no way limited to the hereinabove describedembodiments, but such floor elements may be realized according todifferent variants without leaving the scope of the present invention.

Further, as is clear from the content of the description, the presentinvention relates to one or more of the items as listed below, numberedfrom 1 to 28:

1.—A floor element for forming a floor covering, wherein this floorelement comprises a decorative layer made of a ceramic material and asupport layer arranged below this decorative layer, wherein the supportlayer comprises edges provided with coupling elements configured torealize a mechanical coupling with coupling elements of an adjacentfloor element and wherein the floor element comprises an intermediatelayer having a resin material that permeates a lower surface of thedecorative layer.

2.—The floor element according to item 1, wherein the resin materialcomprises epoxy.

3.—The floor element according to any of the preceding items, whereinthe resin material has a viscosity less than 1000 Pas at 20° C.

4.—The floor element according to any of the preceding items, whereinthe intermediate layer covers 80 percent or more of the lower surface ofthe decorative layer.

5.—The floor element according to any of the preceding items, whereinthe intermediate layer comprises a resin content of at least 150 g/sqm.

6.—The floor element according to any of the preceding items, whereinthe intermediate layer is an adhesive layer that bonds together thedecorative layer and the support layer.

7.—The floor element according to any of the preceding items, whereinthe decorative layer has an apparent porosity comprised between 0.1% and10% measured according to ASTM C373.

8.—The floor element according to any of the preceding items, whereinthe decorative layer has volume of open pores comprised between 0.01 ccand 1 cc measured according to ASTM C373.

9.—The floor element according to any of the preceding items, whereinthe decorative layer comprises a red body ceramic tile.

10.—The floor element according to any of the preceding items, whereinthe decorative layer comprises a glazed upper surface.

11.—The floor element according to any of the preceding items, whereinthe support layer comprises rigid PVC.

12.—The floor element according to any of the preceding items, whereinthe support layer has a flexural modulus between 1.5 and 3.5 GPa.

13.—The floor element according to any of the preceding items, whereinthe support layer has a thickness less than 6 mm.

14.—A floor covering comprising a plurality of floor elements accordingto any of the preceding items.

15.—A method for manufacturing a floor element, comprising the steps of:

providing a decorative layer made of a ceramic material;

providing a support layer;

providing a resin material for bonding the decorative layer and thesupport layer together;

pressing the layers together for forming the floor element such that theresin material permeates the ceramic layer.

16.—The method of item 15, wherein the pressure is kept for a pressingtime of at least 1 second, preferably 30 seconds.

17.—The method according to any of the items 15 or 16, wherein duringthe pressing step it is exerted onto the layers a pressure of at least350 kg/sqm.

18.—Use of a resin material for bonding together a decorative layer madeof a ceramic material and a support layer to form a floor element, theresin material having a viscosity at 20° C. less than 1000 Pas.

19.—Use of a resin material according to item 18, wherein the resinmaterial is epoxy.

20.—A floor element comprising a decorative layer made of a ceramicmaterial, and a support layer arranged below the decorative layer,wherein the support layer comprises at least two couples of oppositeedges comprises coupling elements configured to realize a mechanicalcoupling with coupling elements of adjacent floor elements, whereinfirst coupling elements at a first couple of edges are configured forbeing coupled to the coupling elements of adjacent floor elements bymeans of an angling motion around a horizontal axis parallel to therespective edges, and wherein second coupling elements at a secondcouple of edges are configured for being coupled to the couplingelements of adjacent floor elements by means of an translationaldownward direction of the respective edges towards each other.

21.—Floor element according to item 21, wherein the decorative layer hasdensity as expressed by surface weight of at least 10 kg/sqm, preferablygreater than 15 kg/sqm.

22.—Floor element according to any of the items 20 or 21, wherein thefirsts and the second coupling elements are configured such that saidmechanical coupling results in a locking between said edges in verticaland/or one or more horizontal directions.

23.—Floor element according to any of the items from 20 to 22, whereinin the coupled condition, said first coupling elements are coupled withplay.

24.—Floor element according to item 23, wherein said play is such thatthe first coupling elements may be coupled each other without beingdeformed.

25.—Floor element according to any of the items 23 or 24, wherein saidplay is larger than 0.01 mm and smaller than 0.10 mm.

26.—Floor element according to any of the items from 20 to 25, whereinsaid second coupling elements are deformed during the relative couplingmovement.

27.—A floor element comprising a decorative layer having density asexpressed by surface weight of at least 10 kg/sqm, preferably greaterthan 15 kg/sqm, and a support layer arranged below the decorative,wherein the support layer at least two couples of opposite edgescomprises coupling elements configured to realize a mechanical couplingwith coupling elements of adjacent floor elements, wherein firstcoupling elements at a first couple of edges are configured for beingcoupled to the coupling elements of adjacent floor elements by means ofan angling motion around a horizontal axis parallel to the respectiveedges, and wherein second coupling elements at a second couple of edgesare configured for being coupled to the coupling elements of adjacentfloor elements by means of an translational downward direction of therespective edges towards each other.

28.—Floor element according to item 27, wherein the decorative layer ismade of ceramic, natural stone, concrete, quartz, artificial stone,glass or glass-ceramic material.

While certain systems and methods related to composite tile systems andmethods have been disclosed in some exemplary forms, many modifications,additions, and deletions may be made without departing from the spiritand scope of the system, method, and their equivalents. The embodimentsdisclosed herein are further capable of other embodiments and of beingpracticed and carried out in various ways. Also, it is to be understoodthat the phraseology and terminology employed herein are for thepurposes of description and should not be regarded as limiting theclaims.

Accordingly, those skilled in the art will appreciate that theconception upon which the application and claims are based may bereadily utilized as a basis for the design of other devices, methods,and systems for carrying out the several purposes of the embodiments andclaims presented herein. It is important, therefore, that the claims beregarded as including such equivalent constructions.

What is claimed is:
 1. A floor element for forming a floor covering, thefloor element comprising: a decorative layer made of a brittle material;a support layer arranged below the decorative layer; and an intermediatereinforcing layer, wherein the support layer comprises edges providedwith coupling elements configured to realize a mechanical coupling withcoupling elements of an adjacent floor element, wherein the intermediatereinforcing layer comprises a resin material that permeates a lowersurface of the decorative layer, and wherein the intermediate layer isan adhesive layer that bonds the decorative layer and the support layertogether.
 2. The floor element according to claim 1, wherein thedecorative layer has volume of open pores comprised between 0.01 cc and1 cc measured according to ASTM C373.
 3. The floor element according toclaim 1, wherein the brittle material is selected from the groupconsisting of natural stone, glass, and sintered ceramic materials. 4.The floor element according to claim 1, wherein the decorative layercomprises a ceramic tile.
 5. The floor element according to claim 1,wherein the resin material comprises epoxy.
 6. The floor elementaccording to claim 1, wherein the resin material has a viscosity lessthan 1000 Pas at 20° C.
 7. The floor element according to claim 1,wherein the intermediate reinforcing layer covers 80 percent or more ofa lower surface of the decorative layer.
 8. The floor element accordingto claim 1, wherein the intermediate reinforcing layer comprises a resincontent of at least 150 g/sqm.
 9. The floor element according to claim1, wherein the decorative layer has an apparent porosity comprisedbetween 0.1% and 10% measured according to ASTM.
 10. The floor elementaccording to claim 1, wherein the support layer comprises rigid PVC. 11.The floor element according to claim 10, wherein the support layercomprises more than 30 wt % of fillers.
 12. The floor element accordingto claim 1, wherein the support layer has a flexural modulus between 1.5and 3.5 GPa.
 13. The floor element according to claim 1, wherein thesupport layer is less than 6 mm thick.
 14. The floor element accordingto claim 1, wherein the floor element comprises a superficial area ofless than 1.5 sqm.
 15. The floor element according to claim 1, whereinthe weight of the floor element is at least 18 kg/sqm.
 16. The floorelement according to claim 1, wherein the coupling elements areconfigured in such a way that in a coupled condition a play isestablished between coupled coupling elements.
 17. A floor coveringcomprising a plurality of floor elements according to claim
 1. 18. Amethod for manufacturing a floor element, the method comprising:providing a decorative layer made of a brittle material; providing asupport layer; providing a resin material for bonding the decorativelayer and the support layer together; and pressing the decorative layerand the support layer together for forming the floor element such thatthe resin material permeates the decorative layer.
 19. The method ofclaim 18, wherein the pressure is maintained for a pressing time of atleast 1 second.
 20. The method of claim 18, wherein a pressure of atleast 350 kg/sqm is applied to the decorative layer and the supportlayer during the pressing step.